Abstract: A flame spraying device including a rocket accelerator wherein a low velocity flame is produced into which a coating material is introduced. At least one rocket accelerator producing a high velocity stream of combustion product gases is positioned relative to the low velocity flame so that the coating material carried thereby is accelerated toward the substrate to be coated. By positioning the rocket relative to the low velocity flame, the dwell time in the low velocity flame can be optimized to produce the best coating of a substrate. The coating quality is also enhanced by the fact that the coating material does not oxidize or cool significantly while in the high velocity stream and by the fact that the coating material strikes the substrate at high speed thereby resulting in high density coating.

Abstract: A flame-sprayable flexible wire comprising a mineral powder having a particle size of less than about 140 mesh and about 5 to 70% by volume of the wire of a polyurethane or epoxy polymer. Advantageously the wire is produced by forming the requisite mixture plus a curing agent, effecting a partial cure in a sheet form, crumbling the sheet to coarse granules and extruding the granules to form the wire. The mineral powder particles may first be coated with a surface active resin such as a silicone which promotes adhesion to the polymer and which protects the polymer from the degradative effect of the mineral. The preferred surface active resins are silicones. The wire retains its strength and flexibility over long periods of time and produces high quality flame sprayed surfaces.

Abstract: A flame spray material in the form of a composite comprising (1) as a first component an alloy containing at least about 40% of its weight of at least one of nickel and cobalt, and about 1 to 6% by weight of boron, and (2) aluminum powder as a second component, the first component being present in about 66 to 99% by weight of the composite. The material, desirably blended with about 10% of an aluminum-molybdenum-coated nickel core powder, produces self-bonded wear resistant coatings which can be ground without cracking.